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United States Patent |
5,165,121
|
McTargett
,   et al.
|
November 24, 1992
|
Fabricated faucet spout
Abstract
An improved fabricated faucet is disclosed in which no mounting screws are
visible when the spout is mounted. In a preferred embodiment an under
cover has a notch received on a tab within an internal surface of an upper
cover to secure the two at a forward end. Screws preferably secure the two
at a rearward end, which will be hidden when the spout is mounted. For
longer spouts it may be preferable to use two of the notch and tab
combinations spaced symmetrically about a central axis of the spout. Ribs
formed on the upper cover may abut the under cover to provide additional
rigidity. In another aspect of the present invention, an outlet end
portion of a fluid flow line is received in an outlet port formed through
the under cover. The outlet end portion has threads at an inner periphery
to mount an end effector, such as an aerator or a stream straightener. A
sealing ring is received at the outer periphery of the outlet end portion
to provide a fluid seal between the outlet end and the under cover body.
This allows the faucet spout to be utilized without internal leakage even
if the end effector is removed.
Inventors:
|
McTargett; Charles W. (Indianapolis, IN);
Bendit; Mark A. (Indianapolis, IN);
Marty; Garry R. (Fishers, IN)
|
Assignee:
|
Masco Corporation of Indiana (Taylor, MI)
|
Appl. No.:
|
642627 |
Filed:
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January 17, 1991 |
Current U.S. Class: |
4/678; 137/801 |
Intern'l Class: |
E03C 001/04 |
Field of Search: |
4/191,192
137/801
|
References Cited
U.S. Patent Documents
2781786 | Feb., 1957 | Young | 137/375.
|
3025085 | Mar., 1962 | Young | 4/192.
|
3590876 | Jul., 1971 | Young | 137/801.
|
3871406 | Mar., 1975 | Anderson | 4/191.
|
4649958 | Mar., 1987 | Purcell | 4/191.
|
Primary Examiner: Phillips; Charles E.
Attorney, Agent or Firm: Gossett; Dykema
Claims
We claim:
1. A faucet spout comprising:
a housing formed of an under cover and an upper cover, means for securing
said under cover to said upper cover, said under cover having an outlet
opening;
a fluid line having an inlet and an outlet, said outlet being at an outlet
end portion of said fluid line, said outlet end portion being aligned with
said outlet opening, said outlet end portion having an inner peripheral
surface with means to mount an end effector and an outer peripheral
surface receiving a resilient sealing ring to provide a seal between said
outlet end portion and an inner surface of said under cover; and
said outlet end portion outer peripheral surface including first portion of
a first outer diameter and a second portion upstream of said first portion
of a second diameter greater than said first diameter, said second portion
providing a stop for said seal ring and compressing said seal ring against
said inner surface of said under cover when said under cover is secured to
said upper cover by said means for securing, independently of the presence
of an end effector.
2. A faucet spout as recited in claim 1, wherein said under cover having a
lip received laterally within said upper cover, a notch formed in said lip
at a forward position adjacent said outlet opening, and a tab formed on
said upper cover and extending inwardly from an inner surface, said tab
received in said notch to secure said lip to said upper cover.
3. A faucet spout as recited in claim 1, wherein securing members secure
said under cover to said upper cover near said inlet.
4. A faucet spout as recited in claim 3, wherein said securing members are
hidden by mounting means for said spout when said spout is mounted.
5. A faucet spout as recited in claim 4, wherein said securing members are
screws.
6. A faucet spout as recited in claim 1, wherein said seal is rectangular
in cross-section.
7. A faucet spout as recited in claim 6, wherein said means to mount an end
effector include said outlet end portion being threaded at said inner
peripheral surface.
8. A faucet spout as recited in claim 7, wherein said upper cover having a
member within an inner periphery forcing said outlet end downwardly into
said outlet port in said under cover.
Description
BACKGROUND OF THE INVENTION
This application relates to an improved fabricated faucet spout. More
particularly, the present invention relates to a fabricated faucet spout
that overcomes several limitations in the prior art with regard to both
finished appearance and leakage.
Faucet spouts can be divided into two types. Cast faucet spouts are formed
of a monolithic body of material cast to include internal flow passages.
This type of spout is used in some applications, however, there are
limitations on a cast spout. As an example, the casting methods required
to form such spouts are complicated and expensive.
As an alternative to cast spouts, fabricated spouts are known in the prior
art. A fabricated spout includes a plurality of individual members which
are assembled to complete the final faucet spout. Typically, a housing
having upper and under cover members are secured together to enclose a
fluid flow line. The faucet spout extends longitudinally from an inlet
forwardly to the outlet of the fluid flow line. The upper and under cover
members must be secured together at forward and rearward positions in
order to provide adequate stability to the assembled housing.
Prior art fabricated faucet spouts have used screws, or other attachment
members, which extend through the under cover and into bosses in the upper
cover to secure the two housing parts together. Typically, several screws
extend through screw holes formed at a rearward portion of the under cover
and into bosses in the upper cover. Forward screws extend through screw
holes formed at longitudinally spaced locations along the body of the
under cover in a direction towards the outlet, and into mating bosses in
the upper cover.
Such constructions have several limitations. The screws near the rear
portion of the faucet spout are generally hidden from view once the spout
is mounted to the sink top, but the screws spaced longitudinally forwardly
on the spout are visible when the spout is mounted. This creates
undesirable disruptions in the visual appearance of the spout. Further,
the screws typically may be coated to approximate the finish or color of
the remainder of the spout housing so that they will be less visible. The
screws are preferably off-the-shelf items which must be sent to a treating
process to receive such a finish on their heads. This is time consuming
and expensive.
Further, the bosses formed on the inner surface of the upper cover to
receive screws result in irregularities in the outer surface of the upper
cover. The formation of a boss on an inner surface of the upper cover
typically creates sink marks, or irregularities in the outer surface of
the upper cover, which are undesirable. Also, the concentration of molten
metal in the mold aperture which forms the boss sometimes results in
damage to the mold. For these reasons it would be desirable to reduce the
number of bosses required in the upper cover.
Other problems with the prior art fabricated spouts involve leakage
relating to the connection of end effectors to the outlet of the spout.
Typically, an end effector such as an aerator, a spray straightener, a
nozzle, or any other outlet member, is screwed to a threaded connection
within an outlet end portion of the spout. The threaded connection in the
outlet end portion typically has a lowermost end generally aligned with,
or slightly above, an outlet port in the under cover. It is undesirable to
have the outlet end portion of the fluid flow line extend outwardly of the
outlet port in the undercover, since the flow line is often of a different
finish than the remainder of the faucet housing and is preferably not
visible from outside the spout housing. As such, the end effector usually
extends upwardly into the faucet housing, and into the outlet end portion
where it is secured. This causes leakage problems should the end effector
be removed, since the bottom of the outlet end portion is positioned and
aligned with, or above, the outlet port in the under cover. Water may leak
between the outlet end portion and the under cover into the housing.
Faucets are often operated without end effectors. As an example, when
faucets are initially mounted it is recommended that any end effector be
removed, and water ran through the faucet to clean the flow line. This is
particularly important in home construction, where particles and debris
may clog the line prior to its being mounted. End effectors typically have
small ports which could become clogged with materials that are being
cleaned out of the flow line by this initial flow. Also, end effectors in
public restrooms are often stolen. In either situation the faucet must
operate without an end effector.
It is an object of the present invention to disclose an improved fabricated
faucet spout in which the upper and under cover members are secured
together without any visible screws or other securing members. Further, it
is the object of the present invention to disclose an improved fabricated
spout in which a seal is provided between the outlet end portion of the
flow line and the under cover body such that the faucet may operate
properly without an end effector.
SUMMARY OF THE INVENTION
In a disclosed embodiment of the present invention, an under cover is
secured to an upper cover through known securing members at a rearward
position, adjacent a fluid line inlet, where they are hidden when the
spout is mounted. The forward portions of the upper and under covers are
connected through a notch and tab arrangement. The notch is preferably
formed in a lip in the under cover that extends within a bottom wall of
the upper cover. In this way, no securing members are visible when the
spout is mounted. A disclosed relatively long spout has a pair of notches
and tabs spaced laterally about a central longitudinal axis.
Preferably, the notch is formed as an aperture through a flange extending
upwardly from the main body of the lip with a portion of the flange
extending above the aperture. This portion extends into a channel formed
between the tab and a stop member, with the tab received in the aperture
to provide a secure connection between the upper and under covers.
Preferably, ribs extend from the upper cover downwardly and abut the lip on
the under cover to provide additional rigidity. The number of ribs would
increase with increased spout length.
In another aspect of the present invention the fluid line has an outlet end
portion received in an outlet port formed through the under cover. The
outlet end portion preferably has means at an inner periphery to mount an
end effector, such as an aerator, stream straightener, nozzle, or other
end connection. The outer periphery of the outlet end portion preferably
has a first smaller diameter portion and a second larger diameter portion
spaced upstream from the first portion. A resilient ring is preferably
mounted on the first portion and compressed between the second portion and
an internal face of the under cover. The ring provides a resilient seal
between the bottom of the outlet end portion and the under cover. In this
way, the faucet spout can be utilized without any leakage between the
outlet end portion and the interior of the housing of the spout should the
end effector be removed.
In a most preferred embodiment of the present invention the ring is
preferably square in cross-section and extends for a distance longer than
the first portion such that it is compressed when the upper and under
covers are secured together.
These and other aspects and features of the present invention can be best
understood from the following specification and drawings, of which the
following is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a first embodiment of the invention.
FIG. 2 is a cross-sectional view through the first embodiment illustrated
in FIG. 1.
FIG. 3 is an exploded view of a second embodiment of the present invention.
FIG. 4 is a cross-sectional view through the second embodiment shown in
FIG. 3.
FIG. 5 is an exploded view of a third embodiment of the present invention.
FIG. 6 is a cross-sectional view through the third embodiment illustrated
in FIG. 5.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
FIG. 1 is an exploded view of a first embodiment fabricated spout 20 which
has upper housing, or upper cover 22, secured to under cover 24.
Escutcheon 24 has lip 26 extending in a direction toward upper cover 22,
which fits within lower wall 28 of upper cover 22. Fluid line 30 is
secured between under cover 24 and upper cover 22 and communicates fluid
to an outlet port at a bottom end of outlet end portion 32. Outlet end
portion 32 is received in outlet 34 formed through under cover 24. End
effector 36 is attached to a bottom face of outlet port 32, and may be any
end member such as an aerator or a stream straightener, as are well known
in the prior art. T-connection 38 is attached at an inlet end of fluid
line 30 and receives mixed fluid from a source of both hot and cold water.
Mounting plate 48 secures spout 20 in a mounted position as is well known
in the art, and a plurality of screws 42 extend through screw holes 44
formed in rear bases 46 of under cover 24. Screws 42 extend through holes
44, through mounting plate 48 and are received in bosses 50 formed in an
inner surface of upper cover 22. All four bosses 50 receive screws 42,
which will be hidden from view once spout 20 is mounted to a sink top or
the like. Although screws are disclosed, other securing members, such as
plugs are within the scope of this invention. Further, only the forward
two screws pass through under cover 24. The rearward two screws pass
through plate 48 and into bosses 50. Gasket 40 provides a seal.
Under cover 24 is secured to upper cover 22 at a forward end by the
combination of notch 52 formed in flange 53 extending from a body of lip
26, which is received on tab 54 formed within a forward interior surface
of upper cover 22.
FIG. 2 shows the assembled fabricated faucet spout 20. Screws 42 extend
through holes 44 and into bosses 50. As shown, all screws 42 are hidden
from view in this mounted position. Tab 54 has a stop 56 and flange 53
having notch 52 is received on tab 54 with the portion of flange 53 above
notch 52 received in a channel formed between rib 54 and stop 56. The
channel is formed by a fly cut-out member, which is a type of rotary
cutter. Preferably, a combined rib including members 54 and 56 is
initially molded and the central channel is then cut between the two. Tab
54 received in notch 52 provides sufficient stability to secure under
cover 24 to upper cover 22 at a forward end. Screws 42 secure the two at a
rearward end. Thus, no visible securing members are utilized to secure
under cover 24 to upper cover 22.
Rib 60 extends from upper cover 22 downwardly, and rests on lip 26 of under
cover 24 to add additional stability. Opening 62 may receive a lift rod
actuator handle.
FIG. 3 shows a second fabricated spout 70 including under cover 71 having
lip 72 and notch 73 spaced near a lateral end of flange 74. Flange 74
preferably has a mating notch 73 at an opposed lateral side, facing into
the paper in this figure. Under cover 71 is mounted to upper cover 75
having lower wall 76 which receives lip 72. Flow line 30 is mounted
between under cover 71 and upper cover 75 and has outlet end portion 32
received in outlet 34 formed in under cover 71. Outlet end portion 32 has
a first portion 120 of a smaller diameter and a second portion 77 of a
diameter greater than the first portion and forming a stop for sealing
ring 79 received on first portion 120. Outlet end portion 32 is preferably
received in outlet 34 such that the bottom end of first portion 120 is
roughly aligned with outlet 34 in under cover 71. End effector 36 is then
attached to internal threads in outlet end portion 32. Sealing ring 79 is
received between second portion 77 and the internal surface of under cover
71 to seal a contact surface between under cover 71 and outlet end portion
32. Preferably, ring 79 is square in cross-section and of a length greater
than the length of first portion 120 such that it is compressed to create
a good seal.
Mounting plate 82 mounts faucet 70 as is known. Screws 81 extend through
screw holes 44 formed in bases 46 on under cover 71, and through mounting
plate 82. Other screws 81 extend through plate 82 and into bosses 83 in
upper cover 75. Fluid line 30 is preferably received within mounting plate
82, with nut 84 securing it within aperture 85. Gasket 80 is clipped to
plate 82 to provide a seal.
FIG. 4 is a cross-sectional view of fabricated spout 70. The screws not
shown, extend through screw holes 44 formed in under cover 71 and into
bosses 82 in upper cover 75. Notch 73 is received over tab 84 formed on an
internal forward surface of upper cover 75 and beneath stop 89. It should
be understood that a mating notch and tab combination is spaced on an
opposed lateral side of faucet 70. Further, a pair of ribs 60 rest on lip
72 to provide additional stability to fabricated spout 70.
Seal 79 is received on first portion 120, but extends for a greater
distance than first portion 120 and abuts second portion 77. When under
cover 71 is secured to upper cover 75, rib 58 forces outlet end portion 32
downwardly into outlet 34 and seal 79 is compressed between an internal
surface 88 of under cover 71 and second portion 77. Should end effector 36
be removed, seal 79 would prevent any leakage flow from outlet end 32 into
the interior of the housing of spout 70. Although end effector 36 is shown
connected by threads to outlet end portion 32, it should be understood
that other connecting means would come within the scope of this invention.
A third embodiment fabricated spout 90 is illustrated in FIG. 5. Upper
cover 92 is secured to under cover 94 which has a lip 96 received within
an internal wall of upper cover 92. Tabs 99 and stops 98 are formed at
positions spaced about a longitudinal axis of upper cover 92 and receive
notches 114 formed in flange 113 at a forward end of under cover 94. Fluid
line 30 is also received between upper cover 92 and under cover 94. Screws
103 extend through screw holes 102 in base 100 at a rear portion of under
cover 94 and into bosses 104 formed in upper cover 92.
Seal 106 is received on first portion 107 at a bottom end of outlet end
portion 32. Second portion 108 is of a greater diameter than first portion
107 and provides a stop for seal 106. End effector 110 is connected to
internal threads in outlet end portion 32. Rib 58 forces fluid line 30,
and in particular outlet end portion 32, into under cover 94 which
compresses ring 106 to ensure an adequate seal.
An opening 111 formed in under cover 94 provides access to a set screw 112
which secures fluid line 30 to a fluid supply within the plumbing of the
structure the faucet is connected to. Although this does create an
irregularity in the bottom surface of under cover 94, it is necessary to
properly secure the spout to the structure. The goals of this invention
are still achieved with this embodiment since the number of screw holes
formed in under cover 94 are reduced over the prior art spouts.
FIG. 6 is a cross-sectional view through faucet 90 illustrated in FIG. 5.
Screws 103 extend through screw holes 102 and are received in bosses 104
as described above. Two ribs 60 rest on lip 96 and rib 58 forces outlet
end 32 downwardly into an outlet 34 formed in under cover 94. Outlet end
portion 32 is biased downwardly and compresses seal 106 received on first
portion 107 of outlet end portion 32 between second portion 108 and an
internal surface 112 of under cover 94. Thus, should end effector 110 be
removed there would still be an adequate seal preventing water from
leaking from the outlet into the body of the housing.
Notch 114 is shown received over tab 99 and beneath stop 98 to provide a
connection between under cover 94 and upper cover 92 at a forward end. A
mating connection is formed on an opposed lateral side of faucet 90.
Preferred embodiment of the present invention have been disclosed, however,
a worker of ordinary skill in the art would recognize that certain
modifications would come within the scope of this invention. For that
reason, the following claims should be studied in order to determine the
true scope and contact of this invention.
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